Ces Edupack: Material & Manufacturing Process Selector

MECH 6501 – Advanced Materials
CONCORDIA UNIVERSITY - GINA CODY SCHOOL OF ENGINEERING

AND COMPUTER SCIENCE
MECH-6501/X: Advanced Materials
Copyright © 2021 by Jones & Bartlett Learning, LLC an Ascend Learning Company. www.jblearning.com
Lecture 1b
Material & Manufacturing Process Selector
CES EduPack
Lecture X : THU 2:45 pm – 5:30 pm (FG B040)
Instructor: Sam Eskandarian, Ph.D. PEng (Ontario)
Lecture 1b
Material & Manufacturing Process Selector
CES EduPack
Cambridge Engineering Selector
https://www.ansys.com/products/materials/granta-edupack
Copyright © 2021 by Jones & Bartlett Learning, LLC an Ascend Learning Company. www.jblearning.com.
Outline – Material & Manufacturing Process Selector
1. Material Selection (Ashby’s Method)

o Functional Specifications
o Geometrical Specifications
o Material Properties
2. Quick tour in CES EduPack Software
o Browse (Material & Manufacturing Process Universes)
o Search (Specific Material or Manufacturing Process)
o Select (Combined Material & Process Selection)
3. Manufacturing Process Selection
1 Ashby’s Method for material selection
1.1 Engineering materials and their properties
The families of engineering materials:
• Metals have relatively high moduli. Most, when pure, are
soft and easily deformed.
• Ceramics too, have high moduli, but, unlike metals, they are
brittle.
• Glasses are non-crystalline (‘‘amorphous’’) solids.
• Polymers are at the other end of the spectrum. They have
moduli that are low, roughly 50 times less than those of
metals, but they can be strong—nearly as strong as metals.
• Elastomers are long-chain polymers above their glass-
transition temperature, Tg.
• Hybrids are combinations of two or more materials in a pre-
determined configuration and scale.
Ref: Materials Selection in Mechanical Design, by Michael F. Ashby, 3rd Edition, ELSEVIER, 2005.
1.2 Material properties
1.2 Material properties (Cont’d)
1.2 Material properties (Cont’d)
1.3 Material property Charts
Material properties limit performance. We need
a way of surveying them, to get a feel for the
values design-limiting properties can have. One
property can be displayed as a ranked list or bar-
chart. But it is seldom that the performance of a
component depends on just one property.
Almost always it is a combination of properties

that matter: one thinks, for instance, of the
strength-to-weight ratio, 𝛔f / 𝛒 , or the stiffness-
to-weight ratio, E / 𝛒, that enter light-weight
design. This suggests the idea of plotting one
property against another, mapping out the fields
in property-space occupied by each material
class, and the sub-fields occupied by individual
materials.
1.3 Material property Charts (Cont’d)
Exploring material properties (BROWSE)
The properties of engineering

materials have a characteristic
span of values.
The span can be large: many

properties have values that range
over five or more decades. One
way of displaying this is as a
bar-chart like that of the figure
for thermal conductivity.
Much more information is displayed by an
alternative way of plotting properties,
illustrated in the schematic of the figure.
Here, one property (the modulus, E, in
this case) is plotted against another (the
density, 𝛒) on logarithmic scales.
But by choosing the axes and scales
appropriately, more can be added.
The speed of sound in a solid depends on E
and 𝛒; the longitudinal wave speed v, for
instance, is
For a fixed value of v, this equation plots as a

straight line of slope 1 on the figure. This
allows us to add contours of constant wave
velocity to the chart:
The Modulus–Density chart
Modulus and density are familiar
properties. Steel is stiff, rubber is
compliant: these are effects of
modulus. Lead is heavy; cork is
buoyant: these are effects of
density. The figure shows the full
range of Young’s modulus, E, and
density, 𝛒, for engineering
materials.
1.4 Material Selection
Property constraints and material indices
can be plotted onto them, isolating the
subset of materials that are the best
choice for the design.
1.4 Material Selection (Cont’d)
Transformation of Lines
Material index for a light, strong tie-
rod. A design calls for a cylindrical tie
rod of specified length L to carry a tensile
force F without failure; it is to be of
minimum mass, as in the uppermost
sketch in the figure. The length L is
specified but the cross-section area A is
not. Here, ‘‘maximizing performance’’
means ‘‘minimizing the mass while still
carrying the load F safely’’.
Example
1
Transformation of Lines
Material index for a light, stiff beam.
The mode of loading that most commonly
dominates in engineering is not tension
but bending. Consider, then, a light beam
of square section b × b and length L
loaded in bending. It must meet a
constraint on its stiffness S, meaning that
it must not deflect more than 𝛿 under a
load F.
We find an equation for the stiffness S of an elastic beam.
Example
2
Deriving indices—how to do it
Quick Tour in CES EduPack
2
CES EduPack (Cont’d)
• Young’s modulus of Titanium Alloys?
• Maximum service temperature of ABS?
• Maximum section thickness in Rotational
Molding?
• What tolerances can be achieved in
Electro-discharge machining?
Example
Example
Example
What is Plexi glass (PMMA – Thermoplastic)?

What is Inconel?
•
•
Example
Example
Example
• Classification of materials
!!"
• Which material have the highest ratio ? (Maximum stocking energy per mass of a spring)
"#
• What is the performance index value?
Example
Example
• Select ⊳ New (project stage):
• Limit stage: Selection of material or process by limiting their properties
• Graph stage: Ashby diagram, classification of materials / process
• Tree stage: Coupled study materials/processes
Example
Example
Example
Example
Example
Example
Example: Materials Selection (Assignment #3)
The cylindrical shaft below under torsional stress - Example
Require maximum strength with minimum weight and

minimum cost (for given twisting couple Mt).
Example: Materials Selection
The cylindrical shaft below under torsional stress - Require maximum strength with minimum
weight and minimum cost (for given twisting couple Mt).
Example
Mr pr 4 2M t
t= t and as J = then t=
J 2 pr 3
tf τf 2M t
For a safe design : t max = where N is the safety factor, so; =
N N pr 3
m
Mass, m = πr 2 Lρ , rearranging for r, r = and then substituting this into above eqn for r
pLr
τf 2M t pL3 r 3
= 3
= 2M t then rearrange for m, as we want to reduce m;
N æ m ö m3
p çç ÷
÷
è pLr ø
æ r ö
MATERIAL (depends on material selected,
m = (2 NM t )
23
(p L )
13 ç ÷
çt 2 3 ÷ not design factors)
è f ø
DESIGN (adapted from Callister)

(shape, safety factor, moment etc.)
Example: Materials Selection (Cont.)
Best materials for shaft are those which have a low value of this last expression.
Can quantify a Performance Index (in which a higher number gives better
performance by taking the reciprocal of this expression e.g.
tf 23
P=
r
Now use materials selection chart. Usually log (property) # log (property)
By taking logs of both sides and rearranging the above expression we get a
plot of log(shear strength) against log(density) with a series of straight lines
all of slope 3/2 for different value of P.
P.r = t 2f 3
2
log P + log r = log t f
3
3 3 Vary P (3,10,30,100 etc) and plot on
log P + log r = log t f
2 2 graph.
3 3 (adapted from Callister)
logt f = log r + log P
2 2
Materials on same line

will have same
Performance Index, P.
(in terms of shear
strength and density)
(adapted from Callister)

e.g. require P ³ 10 and

tf ³ 300 MPa.
This identifies search
region - shaded

acceptable
Best

Example : Materials Selection (Cont.)
Lower number Lower number Lowest number

= lower mass = lower cost/kg = most
economical
Shows that 4340 steel is most
economical, even though it was
the worst performer with regard
to mass for sufficient strength.
This analysis has ignored other

considerations that may be
important e.g. stiffness,
corrosion, electrical or thermal
conductivity etc.

3 Processes and process selection
3.1 Classify processes
3.1 Classify processes (Cont’d)
3.2 Systematic process selection
3.2 Systematic process selection (Cont’d)
3.2 Systematic process selection (Cont’d)
3.3 Ranking: Process Cost
If you have to sharpen a pencil, you can do it with a
knife.
If, instead, you had to sharpen a thousand pencils, it
would pay to buy an electric sharpener.
And if you had to sharpen a million, you might wish to
equip yourself with an automatic feeding, gripping, and
sharpening system.
To cope with pencils of different length and diameter,
you could go further and devise a microprocessor-
controlled system with sensors to measure pencil
dimensions, sharpening pressure and so on—an
‘‘intelligent’’ system that can recognize and adapt to
pencil size.
The choice of process, then, depends on the number of
pencils you wish to sharpen, that is, on the batch size.
The best choice is that one that costs least per pencil
sharpened.
3.3 Ranking: Process Cost (Cont’d)
Example
3.4 Computer-aided process selection (CES EduPack)
3.4 Computer-aided process selection (Cont’d)
3.4 Computer-aided process selection (Cont’d)
• Classification of shaping processes by cost index
• Among shaping process for stainless steel, which one has the lowest cost index
for a batch size of 10?
Example

Ces Edupack: Material & Manufacturing Process Selector

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Ces Edupack: Material & Manufacturing Process Selector

Uploaded by

Copyright:

Available Formats

MECH 6501 – Advanced Materials

CONCORDIA UNIVERSITY - GINA CODY SCHOOL OF ENGINEERING

MECH-6501/X: Advanced Materials

1. Material Selection (Ashby’s Method)

Almost always it is a combination of properties

The properties of engineering

The span can be large: many

For a fixed value of v, this equation plots as a

Modulus and density are familiar

We find an equation for the stiffness S of an elastic beam.

What is Plexi glass (PMMA – Thermoplastic)?

Require maximum strength with minimum weight and

DESIGN (adapted from Callister)

Materials on same line

(adapted from Callister)

e.g. require P ³ 10 and

(adapted from Callister)

(adapted from Callister)

Lower number Lower number Lowest number

This analysis has ignored other

(adapted from Callister)

You might also like